Investigation on Indentation Cracking-Based Approaches for Residual Stress Evaluation

Phase-Field Modeling of Fused Silica Cone-Crack Vickers Indentation

In this paper, a 3D phase-field model for brittle fracture is applied for analyzing the complex fracture patterns appearing during the Vickers indentation of fused silica. Although recent phase-field models for the fracture caused by the indentation loading have been verified by some simpler academic axis-symmetric examples, a proper validation of such models is still missing. In addition, heavy computational costs, and a complicated compression stress field under the indenter, which demands different energy decompositions, have been identified as the most important impediments for the successful application of the phase-field method for such problems. An adaptive strategy is utilized for reducing the computational costs, and some modifications are introduced, which enable an accurate simulation of the Vickers indentation fracture. Here, the fracture initiation ring outside the contact zone is detected by using different energy decompositions, and the dominant cone-crack formation under the Vickers indenter is observed. Different contact conditions are investigated. The proposed model is validated by experimental measurements, and a quantitative and qualitative comparison between experimental and numerical results is conducted.

Determination of Mechanical and Fracture Properties of Silicon Single Crystal from Indentation Experiments and Finite Element Modelling

It is well-known that cracks are observed around the impression during indentation of brittle materials. The cracks inception depends on load conditions, material and indenter geometry. The paper aims to use experimental micro-indentation data, FE simulations with cohesive zone modelling, and an optimisation procedure to determine the cohesive energy density of silicon single crystals. While previous studies available in the literature, which use cohesive zone finite element techniques for simulation of indentation cracks in brittle solids, tried to improve methods for the evaluation of material toughness from the indentation load, crack size, hardness, elastic constants, and indenter geometry, this study focuses on the evaluation of the cohesive energy density 2Γ from which the material toughness can be easily determined using the well-known Griffith-Irwin formula. There is no need to control the premise of the linear fracture mechanics that the cohesive zone is much shorter than the crack length. Hence, the developed approach is suitable also for short cracks for which the linear fracture mechanics premise is violated.

Additive Manufacturing of Bulk Metallic Glasses—Process, Challenges and Properties: A Review

Bulk Metallic Glasses (BMG) are metallic alloys that have the ability to solidify in an amorphous state. BMGs show enhanced properties, for instance, high hardness, strength, and excellent corrosion and wear resistance. BMGs produced by conventional methods are limited in size due to the high cooling rates required to avoid crystallization and the associated detrimental mechanical properties. Additive manufacturing (AM) techniques are a potential solution to this problem as the interaction between the heat source, e.g., laser, and the feedstock, e.g., powder, is short and confined to a small volume. However, producing amorphous parts with AM techniques with mechanical properties comparable to as-cast samples remains a challenge for most BMGs, and a complete understanding of the crystallization mechanisms is missing. This review paper tries to cover recent progress in this field and develop a thorough understanding of the correlation between different aspects of the topic. The following subjects are addressed: (i) AM techniques used for the fabrication of BMGs, (ii) particular BMGs used in AM, (iii) specific challenges in AM of BMGs such as the control of defects and crystallization, (iv) process optimization of mechanical properties, and (v) future trends.

Estimation of Residual Stress in Selective Laser Melting of a Zr-Based Amorphous Alloy

An accurate estimation of residual stresses is crucial to ensure dimensional accuracy and prevent premature fatigue failure of 3D printed components. Different from their crystalline counterparts, the effect of residual stress would be worse for amorphous alloys owing to their intrinsic brittleness with low fracture toughness. However, the generation of residual stress and its performance in 3D printed amorphous alloy components still remain unclear. Here, a finite element method combined with experiments and theoretical analyses was introduced to estimate the residual stress in selective laser melting of a Zr-based amorphous alloy. The results revealed that XY cross scanning strategy exhibits relatively low residual stress by comparison with X and Y strategies, and the residual stress becomes serious with increasing bar thickness. The residual stress, on the other hand, could be tuning by annealing or preheating the substrate. The above scenario is thoroughly understood according to the temperature gradient mechanism and its effect on microstructure evaluation.